A Grain Size-Dependent Equation for Creep Rupture Life of Grade 91 Steel Verified Up To 233,000 Hours

<jats:title>Abstract</jats:title> <jats:p>Grade 91 steel is widely used as steam pipes in ultrasupercritical (USC) steam boilers. In residual creep life assessment of the pipes by calculation, one needs creep rupture life of the steel as a function of stress and temperature in a time range longer than 105 h. Four regions with different creep rupture characteristics appear in a stress versus creep rupture life diagram of the steel. Main steam pipes made of the steel are used in a long-term region with low values of stress exponent and activation energy for creep rupture life (referred to as region G in this paper). Creep rupture lives of the steel in this region vary from heat to heat depending on their prior austenite grain size. This paper proposes a grain size-dependent equation representing creep rupture life of the steel in region G. The equation is verified with creep rupture data up to 232,833 h at 600 °C. Region G is absent in some heats with a large grain size. The equation can rationalize the absence in the heats. In a stress versus creep rupture life diagram of grade 92 steel, there is the same long-term region G. In the region, a creep rupture life of each heat is dependent on its grain size as is the case in grade 91 steel. The proposed equation accords well with the creep rupture lives of the grade 92 steel in region G.</jats:p>